In the years since the founding of OFH, we’ve learned a few lessons about the process of designing optical products. Here are a few important ones to keep in mind
Don’t assume an off-the-shelf lens is the lowest cost option
It’s not uncommon to find a custom lens saves money at production volumes as low as 25 units
Do make sure your mechanical engineer has a good understanding of optical tolerances
To manage design trade-offs, a close collaboration between your optical engineer and opto-mechanical engineer is essential
Don’t forget to build into your schedule the time it takes to make custom optics
Custom plastic imaging optics could take as much as 8 months (really!) for mold making. Glass optics are more traditionally 8-10 weeks lead time. Depending on the material and requirements, other options exist for faster prototyping
Don’t assume a Zemax designer who specializes in illumination will also be skilled in imaging designs
Zemax is a powerful tool for designing optics but it can take a long time to become proficient. An engineer who has mastered illumination design will not also be necessarily as skilled in camera lens design
Do make sure you have a good understanding of key lens design trade-offs
Overspecifying your requirements will lead to higher production costs
Don’t assume an off-the-shelf 5 mp camera can actually deliver 5 mp of image quality
The sensor might be 5 mp but if the lens is of low quality, the system will be as well
Do get multiple lens manufacturing quotes
We’ve see quotes for the same part and volume have a 10x price difference among vendors
Do make sure you consider thermal and environmental stress in your design
Depending on your system tolerances and materials used, changes in temperature could degrade optical performance
Don’t assume a final design is ‘final’ until you have sign off from a manufacturer
Different lens vendors prefer different glasses and use different assembly methods. It isn’t unusual for last minute changes to be required
Do look for engineering partners who can deliver turnkey systems including optics, mechanics, and electronics
There is a close interplay between opto-electronics, opto-mechanics, and optics. Having a partner capable of all three reduces the risk of conflict down the road
